Separator for nonaqueous electrolyte battery, and nonaqueous electrolyte battery

ABSTRACT

Provided is a separator for a nonaqueous electrolyte battery, including a porous substrate and an adhesive porous layer that is provided on one side or both sides of the porous substrate and contains an adhesive resin. The ratio of the standard deviation of the areal weight of the adhesive porous layer to the mean of the areal weight of the adhesive porous layer (g/m2) (standard deviation/mean) is 0.3 or less.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 14/413,521filed Jan. 8, 2015, which is a National Stage of InternationalApplication No. PCT/JP2013/070538 filed Jul. 30, 2013 (claiming prioritybased on Japanese Patent Application No. 2012-168989 filed Jul. 30,2012), the contents of which are incorporated herein by reference intheir entirety.

TECHNICAL FIELD

The present invention relates to a separator for a nonaqueouselectrolyte battery and also to a nonaqueous electrolyte battery.

BACKGROUND ART

Nonaqueous secondary batteries, such as lithium ion secondary batteries,have been widely used as power sources for portable electronic devicessuch as laptop computers, mobile phones, digital cameras, andcamcorders. Further, these batteries are characterized by having highenergy density, and thus their application to automobiles and the likehas also been studied in recent years.

With the reduction in size and weight of portable electronic devices,the outer casing of a nonaqueous secondary battery has been simplified.As outer casings, battery cans formed of aluminum cans have beendeveloped to replace battery cans made of stainless steel originallyused. Further, soft pack outer casings formed of aluminum laminate packshave been developed nowadays.

In the case of a soft pack outer casing formed from an aluminumlaminate, because the outer casing is soft, a gap may be formed betweenan electrode and a separator upon charging and discharging. This causesthe reduction of cycle life. The maintenance of uniform adhesion betweenbonded parts of an electrode, a separator, or the like, is one of theimportant technical issues.

As techniques associated with adhesion, various techniques have beenproposed for enhancing adhesion between electrodes and a separator. Asone of such techniques, a technique of using a separator including apolyolefin microporous membrane, which is a conventional separator, anda porous layer made of a polyvinylidene fluoride resin (hereinaftersometimes referred to as “adhesive porous layer”) formed thereon hasbeen proposed (see, e.g., Patent Document 1). When the separator isplaced on an electrode and hot-pressed, the adhesive porous layerfunctions as an adhesive that joins the electrode and the separator welltogether. Therefore, the adhesive porous layer contributes to theimprovement of the cycle life of a soft pack battery.

In relation to the separator including a polyolefin microporous membraneand an adhesive porous layer laminated thereon, for achieving both theensuring of sufficient adhesion and ion permeability, a new technicalproposal has been made focusing on the porous structure and thickness ofthe polyvinylidene fluoride resin layer.

PRIOR ART DOCUMENTS Patent Documents

Patent Document 1: U.S. Pat. No. 4,127,989

SUMMARY OF THE INVENTION Problems that the Invention is to Solve

However, in the case where an adhesive porous layer is to be formed on aporous substrate such as a polyolefin microporous membrane (hereinaftersometimes simply referred to as substrate) by coating, non-uniformitymay result from coating. In other words, variations may occur in thecoat weight. In addition, there usually are variations in the thicknessof a substrate.

In particular, when variations occur in the coat weight of an adhesiveporous layer, variations are likely to occur also in adhesion toelectrodes. Such variations in adhesion are directly related tonon-uniform ion permeability in a battery. Accordingly, in a separator,a part with desired adhesion and a part with reduced adhesion differ inion permeability. When a separator has a part with excellent ionpermeability and a part with poor permeability, the part with high ionpermeability is prone to membrane degradation, causing a significantdecrease in long-term cycle characteristics as the entire battery.

The present invention has been made against the above background. Anobject of the invention is to provide a separator for a nonaqueouselectrolyte battery, which has excellent adhesion to electrodes andprovides a battery with improved cycle characteristics, and also anonaqueous electrolyte battery that stably develops excellent cyclecharacteristics. The invention addresses the achievement of the aboveobject.

Means for Solving the Problems

Specific means for achieving the above object are as follows.

<1> A separator for a nonaqueous electrolyte battery, including a poroussubstrate and an adhesive porous layer that is provided on one side orboth sides of the porous substrate and contains an adhesive resin,

the ratio of the standard deviation of the areal weight of the adhesiveporous layer to the mean of the areal weight of the adhesive porouslayer (g/m²) (standard deviation/mean) being 0.3 or less.

<2> The separator for a nonaqueous electrolyte battery according to <1>,wherein the ratio of the standard deviation of the thickness of theporous substrate to the mean of the thickness of the porous substrate(μm) (standard deviation/mean) is 0.02 or less.<3> The separator for a nonaqueous electrolyte battery according to <1>or <2>, wherein the adhesive resin is a polyvinylidene fluoride resin.<4> The separator for a nonaqueous electrolyte battery according to <3>,wherein the polyvinylidene fluoride resin has a weight average molecularweight of 600,000 or more and 3,000,000 or less.<5> The separator for a nonaqueous electrolyte battery according to anyone of <1> to <4>, wherein the porous substrate has an elongation of 50%or more and 200% or less in the MD direction or the TD direction.<6> The separator for a nonaqueous electrolyte battery according to anyone of <1> to <5>, wherein the porous substrate has a punctureresistance of 200 g or more and 800 g or less.<7> The separator for a nonaqueous electrolyte battery according to anyone of <1> to <6>, wherein the adhesive porous layer contains a filler,and the mass ratio of the filler to the adhesive resin (fillermass/adhesive resin mass) is 0.01 or more and 0.05 or less.<8> A nonaqueous electrolyte battery including a positive electrode, anegative electrode, and the separator for a nonaqueous electrolytebattery of any one of <1> to <7> disposed between the positive electrodeand the negative electrode,

an electromotive force thereof being obtained by lithiumdoping/dedoping.

Advantage of the Invention

The invention provides a separator for a nonaqueous electrolyte battery,which has excellent adhesion to electrodes and provides a battery withimproved cycle characteristics. The invention also provides a nonaqueouselectrolyte battery that stably develops excellent cyclecharacteristics.

MODE FOR CARRYING OUT THE INVENTION

Hereinafter, the separator for a nonaqueous electrolyte battery of theinvention and a nonaqueous electrolyte battery using the same will bedescribed in detail. Incidentally, a numerical range indicated by “to”below means a numerical range including the minimum and the maximum.With respect to the separator for a nonaqueous electrolyte battery ofthe invention, the “MD direction” refers to so-called “machinedirection” and means the longitudinal direction of the separator that isproduced in an elongated form. The “TD direction” refers to so-called“width direction” and means the direction that is perpendicular to thelongitudinal direction of the separator that is produced in an elongatedform.

<Separator for Nonaqueous Electrolyte Battery>

The separator for a nonaqueous electrolyte battery of the inventionincludes a porous substrate and an adhesive porous layer. The adhesiveporous layer is provided on one side or both sides of the poroussubstrate and contains an adhesive resin. The ratio of the standarddeviation of the areal weight of the adhesive porous layer to the meanof the areal weight of the adhesive porous layer [g/m²] (standarddeviation/mean) is 0.3 or less.

With respect to the areal weight of the adhesive porous layer, in thecase where the adhesive porous layer is made only of an adhesive resin,it can be regarded as the areal weight of the adhesive resin in theadhesive porous layer. In the case where the adhesive porous layercontains an adhesive resin and other materials such as a filler, it canbe regarded as the mass of solids forming the adhesive porous layer.

Incidentally, with respect to the areal weight (g/m²) of the adhesiveporous layer or the adhesive resin, in the case where the adhesiveporous layer is provided by coating, it refers to the coat weight afterdrying (g/m²).

In a separator having an adhesive porous layer on a porous substrate,ions are conducted mainly through pores in the separator. Therefore,when there are variations in the thickness of the adhesive porous layer,variations occur in the path length (distance) of ion-conducting pores,and ion permeability cannot be maintained uniform over the entireseparator. When a separator has a region with high ion permeability anda region with poor permeability in this way, the region with high ionpermeability is prone to membrane degradation. As a result, the cyclecharacteristics of the entire battery may be adversely affected.Variations in the areal weight of the adhesive porous layer are one ofthe factors that determine the level of ion permeability. Therefore, inthe invention, variations in the areal weight of the adhesive porouslayer [=(standard deviation of areal weight)/(mean of areal weight)] aresuppressed within a predetermined range. As a result, the adhesion ofthe adhesive porous layer, especially adhesion to electrodes, isimproved, and, when a battery is formed, the long-term cyclecharacteristics are dramatically improved. In addition, becausevariations in the areal weight of the adhesive porous layer are adjustedwithin the range of the invention, when the separator is slit to adesired size, defects caused by slitting can be reduced. As a result,the production yield can be improved.

When the value represented by “(standard deviation of arealweight)/(mean of areal weight)” of the adhesive porous layer is greaterthan 0.3, the areal weight greatly varies in the layer plane direction,leading to non-uniform in-plane ion permeability. This results in asignificant decrease in cycle characteristics when a battery is formed.In addition, defects are likely to occur, such as loss of adhesiveporous layer when the separator is slit.

In the invention, the ratio represented by “(standard deviation of arealweight)/(mean of areal weight)” of the adhesive porous layer is morepreferably 0.2 or less, still more preferably 0.1 or less, and ideallyzero (no variations).

The ratio represented by “(standard deviation of areal weight)/(mean ofareal weight)” of the adhesive porous layer (variations in areal weight)is calculated using the mean and standard deviation obtained from theareal weight (g/m²) of the adhesive porous layer determined as follows.

The areal weight of an adhesive porous layer is measured as follows.That is, ten sample pieces having a size of 10 cm×10 cm cut out from aseparator are prepared, and the areal weight of each sample piece ismeasured. Next, the adhesive porous layer (coating layer) provided oneach sample piece is dissolved away by a solvent, and the areal weightof each porous substrate is measured. Subsequently, the areal weight ofthe porous substrate is subtracted from the areal weight of theseparator to determine the areal weight of the adhesive porous layer ofeach sample piece.

Here, in the invention, the “standard deviation” and the “mean” mean anordinary standard deviation and an ordinary mean, respectively, and aredefined as follows.

That is, in a population made of N data, x₁, x₂, . . . , and x_(N), a“mean” is defined as the arithmetic average of the population(population mean m) as shown by the following equation. That is, in theinvention, the mean of the areal weight of the adhesive porous layer isdetermined by summing areal weight values measured at 10 points of aseparator and dividing the sum by 10.

$\begin{matrix}{m = {\frac{1}{N}{\sum\limits_{i = 1}^{N}\; x_{i}}}} & \left\lbrack {{Equation}\mspace{14mu} 1} \right\rbrack\end{matrix}$

Next, using the population mean m, an unbiased variance σ² is defined asin the following equation.

$\begin{matrix}{\sigma^{2} = {\frac{1}{N - 1}{\sum\limits_{i = 1}^{N}\;\left( {x_{i} - m} \right)^{2}}}} & \left\lbrack {{Equation}\mspace{14mu} 2} \right\rbrack\end{matrix}$

The positive square root σ of the unbiased variance σ² is defined as the“standard deviation.” That is, in the invention, the standard deviationof the areal weight of the adhesive porous layer is obtained by applyinga mean value of areal weights measured at 10 points of a separator tothe above equation to determine the unbiased variance σ², andcalculating the square root thereof.

In the invention, the method for adjusting the ratio of the standarddeviation to mean of the areal weight of an adhesive porous layer to bewithin a range of 0.3 or less may be a method that selects the physicalproperties of a porous substrate, such as variations in the thickness ofthe porous substrate, or selects a porous substrate having suitablephysical properties such as elongation, puncture resistance, tensilestrength, and Young's modulus. Alternatively, in the case where a filleris contained in the adhesive porous layer, it may also be a method thatadjusts the filler content, for example. The adjustment of the physicalproperties of a porous substrate improves the coating stability in theformation of an adhesive porous layer by a coating method, for example,resulting in a uniform coat weight, whereby a highly uniform coatingfilm is obtained.

With respect to the thickness of the porous substrate, in terms ofimproving adhesion to electrodes as a separator, it is preferable thatvariations in the thickness of the porous substrate in the planedirection are suppressed to a certain value or lower. The suppression ofvariations in the thickness reduces variations in ion permeation in theseparator. Specifically, it is preferable that the ratio of “thestandard deviation of the thickness of the porous substrate” to “themean of the thickness [μm]” of the porous substrate (=“(standarddeviation of thickness)/(mean of thickness)”) is adjusted to 0.02 orless.

The ratio of the standard deviation of the thickness of the poroussubstrate to the mean of the thickness of the porous substrate(variations in thickness) is calculated using the mean and standarddeviation obtained from the thickness (μm) of the porous substratedetermined as follows.

The thickness of a porous substrate is measured as follows. That is, theporous substrate is cut to a size of 10 cm×10 cm, and ten sample piecesare prepared. The center of each sample piece in the width direction(TD) is measured for thickness at 10 points at intervals of 1 cm in thelength direction (MD) to give thickness data at 100 points in total.Then, based on the thickness data at 100 points, the mean and standarddeviation are calculated in the same manner as in the case of the arealweight mentioned above. For the measurement of thickness, a contactthickness meter (e.g., LITEMATIC manufactured by Mitutoyo Corporation)is used. A cylindrical terminal 5 mm in diameter is used as a measuringterminal, and it is adjusted to apply a load of 7 g during themeasurement.

When the value represented by “(standard deviation of thickness)/(meanof thickness)” in the porous substrate is 0.02 or less, plane-directionthickness variations in a layer provided on the substrate can be madesmall, whereby the path length (distance) of ion-conducting poresbecomes even more uniform. This results in uniform in-plane ionpermeability, and cycle characteristics as a battery can be stablymaintained for a long period of time.

The ratio represented by “(standard deviation of thickness)/(mean ofthickness)” is more preferably 0.01 or less, still more preferably 0.005or less, and ideally zero (no variations).

The technique for controlling variations in the thickness of the poroussubstrate is not particularly limited. For example, it is possible toselect a commercially available porous substrate that satisfies thethickness conditions mentioned above.

[Porous Substrate]

The porous substrate in the invention means a substrate having pores orvoids inside. Examples of such substrates include microporous membranes,porous sheets made of a fibrous material, such as nonwoven fabrics andpaper-like sheets, and composite porous sheets including such amicroporous membrane or porous sheet as well as one or more other porouslayers laminated thereon.

A microporous membrane means a membrane having a large number ofmicropores inside and configured such that the micropores are connectedto allow gas or liquid to pass from one side to the other side.

The material forming the porous substrate may be an organic material oran inorganic material as long as it is an electrically insulatingmaterial. In terms of imparting a shutdown function to the poroussubstrate, it is preferable that the material forming the poroussubstrate is a thermoplastic resin.

A shutdown function refers to the following function: upon an increasein battery temperature, a constituent material melts and closes pores ofthe porous substrate, thereby blocking the movement of ions to preventthe battery from thermal runaway.

As the thermoplastic resin, a thermoplastic resin having a melting pointof less than 200° C. is suitable, and polyolefins are particularlypreferable.

As a porous substrate using a polyolefin, a polyolefin microporousmembrane is preferable.

As the polyolefin microporous membrane, among polyolefin microporousmembranes that have been applied to conventional separators for anonaqueous electrolyte battery, one having sufficient dynamic propertiesand ion permeability can be preferably used.

In terms of developing a shutdown function, it is preferable that thepolyolefin microporous membrane contains polyethylene, and it ispreferable that the polyethylene content is 95 mass % or more.

In addition to the above, in terms of imparting heat resistance thatprevents the membrane from easily breaking when exposed to hightemperatures, a polyolefin microporous membrane containing polyethyleneand polypropylene is preferable. An example of such a polyolefinmicroporous membrane is a microporous membrane in which bothpolyethylene and polypropylene are present in one layer. In terms ofachieving both a shutdown function and heat resistance, it is preferablethat the microporous membrane contains 95 mass % or more polyethyleneand 5 mass % or less polypropylene. In addition, in terms of achievingboth a shutdown function and heat resistance, it is also preferable thatthe polyolefin microporous membrane has a laminated structure includingtwo or more layers, in which at least one layer contains polyethylene,while at least one layer contains polypropylene.

It is preferable that the polyolefin contained in the polyolefinmicroporous membrane has a weight average molecular weight of 100,000 to5,000,000. When the weight average molecular weight is 100,000 or more,sufficient dynamic properties can be ensured. Meanwhile, a weightaverage molecular weight of 5,000,000 or less leads to excellentshutdown characteristics and also facilitates membrane formation.

A polyolefin microporous membrane can be produced by the followingmethods, for example. That is, a method including (i) extruding a moltenpolyolefin resin from a T-die to form a sheet, (ii) subjecting the sheetto a crystallization treatment, (iii) stretching the same, and further(iv) heat-treating the stretched sheet to form a microporous membranecan be mentioned. As an alternative method, a method including (i)melting a polyolefin resin together with a plasticizer such as liquidparaffin and extruding the melt from a T-die, followed by cooling toform a sheet, (ii) stretching the sheet, (iii) extracting theplasticizer from the stretched sheet, and further (iii) heat-treatingthe sheet to form a microporous membrane can also be mentioned, forexample.

Examples of porous sheets made of a fibrous material include poroussheets made of fibrous materials, for example, polyesters such aspolyethylene terephthalate; polyolefins such as polyethylene andpolypropylene; and heat-resistant polymers such as aromatic polyamide,polyimide, polyethersulfone, polysulfone, polyether ketone, andpolyetherimide. Examples also include porous sheets made of a mixture ofthese fibrous materials.

A composite porous sheet may be configured to include a microporousmembrane or a porous sheet made of a fibrous material as well as afunctional layer laminated thereon. The composite porous sheet ispreferable in that further functions can be imparted by the functionallayer. In terms of imparting heat resistance, for example, thefunctional layer may be a porous layer made of a heat-resistant resin ora porous layer made of a heat-resistant resin and an inorganic filler.The heat-resistant resin may be one or more kinds of heat-resistantpolymers selected from aromatic polyamide, polyimide, polyethersulfone,polysulfone, polyether ketone, and polyetherimide. As the inorganicfiller, metal oxides such as alumina, metal hydroxides such as magnesiumhydroxide, and the like can be preferably used.

Incidentally, examples of compositing techniques include a method inwhich a microporous membrane or a porous sheet is coated with afunctional layer, a method in which a microporous membrane or a poroussheet and a functional layer are joined together using an adhesive, anda method in which a microporous membrane or a porous sheet and afunctional layer are bonded together by thermocompression.

As mentioned above, in terms of adjusting the ratio of the standarddeviation of the areal weight of the adhesive resin to the mean of theareal weight of the adhesive resin to be within a range of 0.3 or less,it is preferable that the elongation, puncture resistance, tensilestrength, and Young's modulus of the porous substrate are adjusted to bewithin the following ranges, for example.

It is preferable that the porous substrate has an elongation of 50% ormore and 200% or less in the MD direction or the ID direction. The lowerlimit is more preferably 80% or more, and still more preferably 100% ormore. The upper limit is preferably 180% or less, and more preferably150% or less.

It is preferable that the porous substrate has a puncture resistance of200 g or more and 800 g or less. The lower limit is more preferably 250g or more, and still more preferably 300 g or more. The upper limit ispreferably 700 g or less, and preferably 600 g or less.

It is preferable that the porous substrate has a tensile strength of 1N/cm or more and 25 N/cm or less in the MD direction or the TDdirection. The lower limit is more preferably 3 N/cm or more, and stillmore preferably 5 N/cm or more. The upper limit is preferably 22 N/cm orless, and preferably 20 N/cm or less.

It is preferable that the porous substrate has a Young's modulus of 800MPa or more and 5,000 MPa or less. The lower limit is more preferably900 MPa or more, and still more preferably 1,000 MPa or more. The upperlimit is preferably 4,000 MPa or less, and preferably 3,000 MPa or less.

A Young's modulus is the amount of elastic deformation in response tothe application of force within a range where elasticity is shown, thatis, the stress required per unit strain, and is equivalent to, forexample, the slope of the linear portion of a stress-strain curveobtained by plotting stress on the ordinate against strain on theabscissa. A Young's modulus is determined by the following equation fromthe relation of the amount of strain to the direction of stress underunidirectional tension or compression.E=σ/ε [E: Young's modulus, σ: strain, ε: stress]

In terms of obtaining excellent dynamic properties and internalresistance, it is preferable that the porous substrate has a thickness(mean) within a range of 5 μm to 25 μm.

In terms of preventing short circuits in a battery and obtainingsufficient ion permeability, it is preferable that the porous substratehas a Gurley number (JIS P8117) within a range of not less than 50sec/100 cc and not more than 800 sec/100 cc.

[Adhesive Porous Layer]

The adhesive porous layer in the invention is a layer having a porousstructure in which a large number of micropores are present inside, andthe micropores are connected to each other to allow gas or liquid topass from one side to the other side. The porous structure of theadhesive porous layer is an important technical factor.

The adhesive porous layer is provided as the outermost layer(s) of theseparator on one side or both sides of the porous substrate. Theadhesive porous layer allows for bonding to an electrode. That is, whenthe separator and an electrode are stacked and hot-pressed, the adhesiveporous layer can bond the separator to the electrode. In the case wherethe separator for a nonaqueous electrolyte battery of the invention hasthe adhesive porous layer only on one side of the porous substrate, theadhesive porous layer adheres to the positive electrode or the negativeelectrode. In addition, in the case where the separator for a nonaqueouselectrolyte battery of the invention has the adhesive porous layer onboth sides of the porous substrate, the adhesive porous layer adheres toboth the positive electrode and the negative electrode. In terms ofproviding a battery with excellent cycle characteristics, it ispreferable that the adhesive porous layer is provided on both sides ofthe porous substrate rather than only one side. This is because when theadhesive porous layer is present on both sides of the porous substrate,both sides of the separator adhere well to both electrodes via theadhesive porous layer.

In the invention, in the case where the adhesive porous layer is appliedto and formed on both sides of the porous substrate, the coat weight ofthe adhesive porous layer (mean of areal weight) on one side of theporous substrate is preferably 0.5 g/m² to 1.5 g/m², and more preferably0.7 g/m² to 1.3 g/m². When the coat weight is 0.5 g/m² or more, thisleads to excellent adhesion to electrodes, providing a battery withexcellent cycle characteristics. Meanwhile, when the coat weight is 1.5g/m² or less, this makes it easy to suppress variations in the coatweight of the adhesive porous layer within the above range, wherebyexcellent ion permeability is ensured, providing a battery with goodload characteristics.

In the case where the adhesive porous layer is provided on both sides ofthe porous substrate, the difference between the coat weight on one sideand the coat weight on the other side is preferably 20% or less of thetotal coat weight on both sides. When the difference is 20% or less, theseparator is resistant to curling. This results in good handleability,and also the problem of decreased cycle characteristics is unlikely tooccur.

It is preferable that the thickness of the adhesive porous layer on oneside of the porous substrate is 0.3 μm to 5 μm. When the thickness is0.3 μm or more, this makes it easy to suppress variations in the coatweight of the adhesive porous layer within the above range, and leads toeven better adhesion to electrodes, providing a battery with excellentcycle characteristics. When the thickness is 5 μm or less, even betterion permeability is ensured, providing a battery with excellent loadcharacteristics. For the same reason as above, the thickness of theadhesive porous layer on one side of the porous substrate is morepreferably 0.5 μm to 5 μm, and still more preferably 1 μm to 2 μm.

In the invention, in terms of ion permeability, it is preferable thatthe structure of the adhesive porous layer is sufficiently porous.Specifically, it is preferable that the porosity is 30% to 60%. When theporosity is 30% or more, ion permeability is excellent, leading to evenbetter battery characteristics. In addition, a porosity of 60% or lessprovides dynamic properties sufficient to prevent the porous structurefrom being destroyed upon bonding to an electrode by hot pressing. Inaddition, a porosity of 60% or less provides low surface porosity,leading to an increase in the area occupied by the adhesive resin(preferably polyvinylidene fluoride resin), whereby even better adhesionstrength can be ensured. Incidentally, it is more preferable that theporosity of the adhesive porous layer is within a range of 30 to 50%.

It is preferable that the adhesive porous layer has an average pore sizeof 1 nm to 100 nm. When the average pore size of the adhesive porouslayer is 100 nm or less, a porous structure in which uniform pores areuniformly dispersed is likely to be obtained, whereby points of bondingto an electrode can be uniformly dispersed, resulting in excellentadhesion. This also results in uniform ion migration. Thus, even bettercycle characteristics can be obtained, and also further excellent loadcharacteristics can be obtained. Meanwhile, although it is preferable,in terms of uniformity, that the average pore size is as small aspossible, it is practically difficult to form a porous structure of lessthan 1 nm. In addition, in the case where the adhesive porous layer isimpregnated with an electrolyte, the resin (e.g., polyvinylidenefluoride resin) may swell, and, when the average pore size is too small,the pores may be closed due to swelling, resulting in loss of ionpermeability. Also from such a point of view, it is preferable that theaverage pore size is 1 nm or more.

The average pore size of the adhesive porous layer is more preferably 20nm to 100 nm.

In terms of cycle characteristics, it is preferable that thepolyvinylidene fluoride resin in the adhesive porous layer has a fibrildiameter within a range of 10 nm to 1,000 nm.

The adhesive porous layer in the invention contains at least an adhesiveresin and preferably contains a filler. In addition, the adhesive porouslayer may be formed further using other components as necessary.

(Adhesive Resin)

The adhesive resin contained in the adhesive porous layer is notparticularly limited as long as it can adhere to electrodes. Preferredexamples thereof include polyvinylidene fluoride, polyvinylidenefluoride copolymers, styrene-butadiene copolymers, homopolymers andcopolymers of vinyl nitriles such as acrylonitrile andmethacrylonitrile, and polyethers such as polyethylene oxide andpolypropylene oxide.

The adhesive porous layer may contain only one kind of adhesive resin,or may also contain two or more kinds.

In terms of adhesion to electrodes, it is particularly preferable thatthe adhesive resin is a polyvinylidene fluoride resin.

Examples of polyvinylidene fluoride resins include a homopolymer ofvinylidene fluoride (i.e., polyvinylidene fluoride); copolymers ofvinylidene fluoride and another copolymerizable monomer (polyvinylidenefluoride copolymers); and mixtures thereof.

Examples of monomers copolymerizable with vinylidene fluoride includetetrafluoroethylene, hexafluoropropylene (HFP), trifluoroethylene,trichloroethylene, and vinyl fluoride. They can be used alone, or it isalso possible to use two or more kinds.

A polyvinylidene fluoride resin is obtained by emulsion polymerizationor suspension polymerization.

Among polyvinylidene fluoride resins, in terms of adhesion toelectrodes, copolymers copolymerized with at least vinylidene fluorideand hexafluoropropylene are preferable. Further, copolymers having astructural unit derived from vinylidene fluoride and a structural unitderived from hexafluoropropylene in an amount of 0.1 mol % or more and 5mol % or less (preferably 0.5 mol % or more and 2 mol % or less) by massare more preferable.

It is preferable that the polyvinylidene fluoride resin has a structuralunit containing 98 mol % or more vinylidene fluoride. In the case where98 mol % or more of vinylidene fluoride is present, dynamic propertiesand heat resistance sufficient for severe hot-pressing conditions can beensured.

It is preferable that the adhesive resin (especially polyvinylidenefluoride resin) has a weight average molecular weight (Mw) within arange of 600,000 to 3,000,000. When the weight average molecular weightis 600,000 or more, dynamic properties that can withstand the treatmentfor bonding to electrodes can be ensured for the adhesive porous layer,and sufficient adhesion can be obtained. Meanwhile, when the weightaverage molecular weight is 3,000,000 or less, viscosity at the time offormation of the layer does not become too high, leading to goodformability and crystal formation, resulting in excellent porousness.The lower limit of the weight average molecular weight is morepreferably 700,000 or more, and still more preferably 800,000 or more.The upper limit of the weight average molecular weight is preferably2,000,000 or less, and preferably 1,500,000 or less.

Incidentally, the weight average molecular weight (Dalton) of theadhesive resin is a polystyrene-equivalent molecular weight measured bygel permeation chromatography (hereinafter sometimes referred to as GPC)under the following conditions.

<Conditions>

GPC: Alliance GPC 2000 [manufactured by Waters Corporation]

Column: TSKgel GMH₆-HTx2+TSKgel GMH₆-HTLx2 [manufactured by TosohCorporation]

Mobile phase solvent: o-Dichlorobenzene

Reference sample: Monodisperse polystyrene [manufactured by TosohCorporation]

Column temperature: 140° C.

When the adhesive porous layer is impregnated with an electrolyte, thedegree of swelling of the resin contained in the adhesive porous layerdepends on the kind of resin or the electrolyte composition. In order tosuppress defects caused by the swelling of the resin, it is preferableto select a polyvinylidene fluoride resin that is resistant to swelling.For example, a polyvinylidene fluoride resin containing a large amountof copolymer component is prone to swelling, while a polyvinylidenefluoride resin containing 98 mol % or more vinylidene fluoride isresistant to swelling and thus preferable.

In addition, a polyvinylidene fluoride resin is prone to swelling withan electrolyte having a high content of cyclic carbonate, such asethylene carbonate or propylene carbonate, and a high dielectricconstant. However, a polyvinylidene fluoride resin containing 98 mol %or more vinylidene fluoride is relatively resistant to swelling and thuspreferable.

(Filler)

The adhesive porous layer may contain a filler made of an inorganicsubstance or an organic substance. When the adhesive porous layercontains a filler, the slidability and heat resistance of the separatorare improved.

Examples of inorganic fillers include metal oxides such as alumina andmetal hydroxides such as magnesium hydroxide. In addition, examples oforganic fillers include acrylic resins.

It is preferable that the mass ratio of the filler to the adhesive resin(filler mass/adhesive resin mass) is 0.01 or more and 0.05 or less. Theadjustment of the filler content in this way makes it easy to adjust thevalue represented by “(standard deviation of areal weight)/(mean ofareal weight)” of the adhesive porous layer to be within the range ofthe invention.

[Characteristics of Separator]

In terms of mechanical strength and of energy density as a battery, itis preferable that the separator for a nonaqueous electrolyte battery ofthe invention has an entire thickness of 5 μm to 35 μm.

In terms of mechanical strength, handleability, and ion permeability, itis preferable that the separator for a nonaqueous electrolyte battery ofthe invention has a porosity of 30% to 60%.

In terms of achieving a good balance between mechanical strength andmembrane resistance, it is preferable that the separator for anonaqueous electrolyte battery of the invention has a Gurley number (JISP8117) of 50 sec/100 cc to 800 sec/100 cc.

In terms of ion permeability, in the separator for a nonaqueouselectrolyte battery of the invention, it is preferable that thedifference between the Gurley number of the porous substrate and theGurley number of the separator including the porous substrate and anadhesive porous layer provided thereon is not more than 300 sec/100 cc,more preferably not more than 150 sec/100 cc, and still more preferablynot more than 100 sec/100 cc.

In terms of the load characteristics of a battery, it is preferable thatthe separator for a nonaqueous electrolyte battery of the invention hasa membrane resistance of 1 ohm-cm² to 10 ohm-cm². Membrane resistanceherein refers to the resistance of the separator as impregnated with anelectrolyte, and is measured by an alternating-current method. Theresistance naturally depends on the kind of electrolyte and thetemperature, and the above value is a value measured at 20° C. using 1 MLiBF₄-propylene carbonate/ethylene carbonate (mass ratio: 1/1) as theelectrolyte.

In terms of ion permeability, it is preferable that the separator for anonaqueous electrolyte battery of the invention has a tortuosity of 1.5to 2.5.

<Method for Producing Separator>

The separator for a nonaqueous electrolyte battery of the invention canbe produced, for example, by a method in which a porous substrate iscoated thereon with a coating liquid containing an adhesive resin, suchas a polyvinylidene fluoride resin, to form a coating layer, and thenthe resin of the coating layer is solidified, thereby integrally formingan adhesive porous layer on the porous substrate.

The following describes the case where the adhesive porous layer isformed using a polyvinylidene fluoride resin.

An adhesive porous layer using a polyvinylidene fluoride resin as anadhesive resin can be preferably formed by the following wet coatingmethod, for example.

The wet coating method is a film formation method including (i) a stepof dissolving a polyvinylidene fluoride resin in a suitable solvent toprepare a coating liquid, (ii) a step of coating a porous substrate withthe coating liquid, (iii) a step of immersing the porous substrate in asuitable coagulation liquid to induce phase separation and solidify thepolyvinylidene fluoride resin, (iv) a step of washing with water, and(v) a step of drying, thereby forming a porous layer on the poroussubstrate. The detail of the wet coating method suitable for theinvention is as follows.

As a solvent that dissolves a polyvinylidene fluoride resin (hereinaftersometimes referred to as “good solvent”) used for the preparation of acoating liquid, it is preferable to use a polar amide solvent such asN-methylpyrrolidone, dimethylacetamide, or dimethylformamide.

In terms of forming an excellent porous structure, in addition to thegood solvent, it is preferable to mix a phase separation agent thatinduces phase separation. Examples of phase separation agents includewater, methanol, ethanol, propyl alcohol, butyl alcohol, butanediol,ethylene glycol, propylene glycol, and tripropylene glycol. It ispreferable that the phase separation agent is added within a range whereviscosity suitable for coating can be ensured.

In terms of forming an excellent porous structure, it is preferable thatthe solvent is a mixed solvent containing 60 mass % or more a goodsolvent and 40 mass % or less a phase separation agent.

In terms of forming an excellent porous structure, it is preferable thatthe coating liquid contains the polyvinylidene fluoride resin at aconcentration of 3 to 10 mass %.

In the case where a filler or other components are added to the adhesiveporous layer, they may be mixed with or dissolved in the coating liquid.

In general, a coagulation liquid contains the good solvent and phaseseparation agent used for the preparation of a coating liquid and water.In terms of production, it is preferable that the mixing ratio betweenthe good solvent and the phase separation agent is determined accordingto the mixing ratio in the mixed solvent used for dissolving apolyvinylidene fluoride resin. In terms of the formation of a porousstructure and productivity, it is suitable that the concentration ofwater is 40 mass % to 90 mass %.

The coating of a porous substrate with the coating liquid may beperformed using a conventional coating technique, such as a Mayer bar, adie coater, a reverse roll coater, or a gravure coater. In the casewhere an adhesive porous layer is formed on both sides of the poroussubstrate, in terms of productivity, it is preferable that both sides ofthe substrate are simultaneously coated with the coating liquid.

In addition to the wet coating method mentioned above, the adhesiveporous layer can be produced by a dry coating method. Here, the drycoating method is a method in which, for example, a porous substrate iscoated with a coating liquid containing a polyvinylidene fluoride resinand a solvent, and then the resulting coating layer is dried tovolatilize the solvent away, thereby giving a porous layer. However, ascompared with the wet coating method, the dry coating method tends togive a dense coating layer. Accordingly, the wet coating method is morepreferable in terms of obtaining an excellent porous structure.

The separator for a nonaqueous electrolyte battery of the invention canalso be produced by a method in which an adhesive porous layer is formedas an independent sheet, then the adhesive porous layer is placed on aporous substrate, and they are composited by thermocompression bondingor using an adhesive. The method for producing an adhesive porous layeras an independent sheet may be a method in which a release sheet iscoated thereon with a coating liquid containing a resin, then anadhesive porous layer is formed by the wet coating method or dry coatingmethod mentioned above, and the adhesive porous layer is peeled off fromthe release sheet.

<Nonaqueous Electrolyte Battery>

The nonaqueous electrolyte battery of the invention is a nonaqueouselectrolyte battery whose electromotive force is obtained by lithiumdoping/dedoping, and is configured to include a positive electrode, anegative electrode, and the separator for a nonaqueous electrolytebattery of the invention mentioned above. Incidentally, doping meansocclusion, support, adsorption, or intercalation, and refers to thephenomenon that lithium ions enter the active material of an electrodesuch as a positive electrode.

The nonaqueous electrolyte battery is configured such that a batteryelement, which includes an electrolyte-impregnated structure having thenegative electrode and the positive electrode facing each other via theseparator, is enclosed in an outer casing material. The nonaqueouselectrolyte battery of the invention is suitable for a nonaqueouselectrolyte secondary battery, particularly a lithium ion secondarybattery.

The nonaqueous electrolyte battery of the invention includes, as aseparator, the separator for a nonaqueous electrolyte battery of theinvention mentioned above, and thus is excellent in terms of adhesionbetween the electrodes and the separator. At the same time, the yield ofthe production process is high, and electrolyte retention is alsoexcellent. Accordingly, the nonaqueous electrolyte battery of theinvention develops stable cycle characteristics.

The positive electrode may be configured such that an active materiallayer containing a positive electrode active material and a binder resinis formed on a collector. The active material layer may further containan electrically conductive auxiliary.

Examples of positive electrode active materials includelithium-containing transition metal oxides. Specific examples thereofinclude LiCoO₂, LiNiO₂, LiMn_(1/2)Ni_(1/2)O₂,LiCo_(1/3)Mn_(1/3)Ni_(1/3)O₂, LiMn₂O₄, LiFePO₄, LiCo_(1/2)Ni_(1/2)O₂,and LiAl_(1/4)Ni_(3/4)O₂.

Examples of binder resins include polyvinylidene fluoride resins andstyrene-butadiene copolymers.

Examples of electrically conductive auxiliaries include carbon materialssuch as acetylene black, ketjen black, and graphite powder.

Examples of collectors include aluminum foils, titanium foils, andstainless steel foils having a thickness of 5 μm to 20 μm.

In the nonaqueous electrolyte battery of the invention, in the casewhere the separator includes an adhesive porous layer containing apolyvinylidene fluoride resin, and the adhesive porous layer is disposedon the positive electrode side, because the polyvinylidene fluorideresin has excellent oxidation resistance, a positive electrode activematerial that can be operated at a high voltage of 4.2 V or more, suchas LiMn_(1/2)Ni_(1/2)O₂ or LiCo_(1/3)Mn_(1/3)Ni_(1/3)O₂, can be easilyapplied; thus, this is advantageous.

The negative electrode may be configured such that an active materiallayer containing a negative electrode active material and a binder resinis formed on a collector. The active material layer may further containan electrically conductive auxiliary.

Examples of negative electrode active materials include materialscapable of electrochemically occluding lithium. Specific examplesthereof include carbon materials, silicon, tin, aluminum, and Wood'salloy.

Examples of binder resins include polyvinylidene fluoride resins andstyrene-butadiene copolymers.

Examples of electrically conductive auxiliaries include carbon materialssuch as acetylene black, ketjen black, and graphite powder.

Examples of collectors include copper foils, nickel foils, and stainlesssteel foils having a thickness of 5 μm to 20 μm.

In addition, instead of such a negative electrode, a metal lithium foilmay also be used as the negative electrode.

The electrolyte is a solution obtained by dissolving a lithium salt in anonaqueous solvent.

Examples of lithium salts include LiPF₆, LiBF₄, and LiClO₄.

Examples of nonaqueous solvents include cyclic carbonates such asethylene carbonate, propylene carbonate, fluoroethylene carbonate, anddifluoroethylene carbonate; linear carbonates such as dimethylcarbonate, diethyl carbonate, ethyl methyl carbonate, and fluorinesubstitutions thereof; and cyclic esters such as γ-butyrolactone andγ-valerolactone. They may be used alone or as a mixture.

As the electrolyte, one obtained by mixing a cyclic carbonate and alinear carbonate in a mass ratio (cyclic carbonate/linear carbonate) of20/80 to 40/60 and dissolving a lithium salt therein at 0.5 M to 1.5 Mis preferable.

Examples of outer casing materials include metal cans and packs formedfrom an aluminum laminate film.

The shape of batteries may be prismatic, cylindrical, coin-type, etc.,and the separator for a nonaqueous electrolyte battery of the inventionis suitable for any shape.

EXAMPLES

Hereinafter, the invention will be described in further detail withreference to examples. However, within the gist thereof, the inventionis not limited to the following examples.

[Measurement/Evaluation]

Separators and lithium ion secondary batteries produced in the followingexamples and comparative examples were subjected to the followingmeasurements and evaluations.

(Mean and Standard Deviation of Thickness)

The thickness of a separator or a porous substrate was measured asfollows. First, a separator or a porous substrate was cut to a size of10 cm×10 cm, and ten sample pieces were prepared. The center of eachsample piece in the width direction (TD) was measured for thickness at10 points at intervals of 1 cm in the length direction (MD) to givethickness data at 100 points in total. Then, based on the thickness dataat 100 points, the mean and standard deviation were calculated. For themeasurement of thickness, a contact thickness meter (e.g., LITEMATICmanufactured by Mitutoyo Corporation) was used. A cylindrical terminal 5mm in diameter was used as a measuring terminal, and it was adjusted toapply a load of 7 g during the measurement.

(Mean and Standard Deviation of Areal Weight)

Ten sample pieces having a size of 10 cm×10 cm cut out from a separatorwere prepared, and the mass of each sample piece was measured. The masswas divided by the area to determine the areal weight of each separator.Next, the adhesive porous layer (coating layer) provided on each samplepiece was dissolved away by a solvent, and the mass of the poroussubstrate was measured. The mass was divided by the area to determinethe areal weight of the porous substrate. Subsequently, the areal weightof the porous substrate was subtracted from the areal weight of theseparator to determine the areal weight of the adhesive porous layer ofeach sample piece. Based on the areal weight data of the adhesive porouslayer at 10 points, the mean and standard deviation of areal weight werecalculated.

The ratio of the standard deviation of the areal weight of the adhesiveporous layer to the mean of the areal weight of the adhesive porouslayer (variations in areal weight) was obtained by dividing the standarddeviation by mean of the areal weight (g/m²) of the adhesive porouslayer determined as above.

(Standard Deviation/Mean of Thickness of Porous Substrate)

The ratio of the standard deviation of the thickness of a poroussubstrate to the mean of the thickness of the porous substrate(variations in thickness) was calculated using the mean and standarddeviation of the thickness (μm) of the porous substrate determined asabove.

(Tensile Strength)

The tensile strength of a porous substrate or a separator was measuredas follows. Using a tensile tester (RTC-1225A manufactured by A&DCompany), a sample adjusted to 10 mm×100 mm was subjected to measurementunder the following conditions: load cell load: 5 kgf, chuck-to-chuckdistance: 50 mm, tensile rate: 100 mm/min. The stress at break was takenas tensile strength.

(Elongation)

The elongation of a porous substrate or a separator was measured asfollows. Using a tensile tester (RTC-1225A manufactured by A&D Company),a sample adjusted to 10 mm×100 mm was subjected to measurement under thefollowing conditions: load cell load: 5 kgf, chuck-to-chuck distance: 50mm, tensile rate: 100 mm/min. The chuck-to-chuck distance at break wasdivided by the initial chuck-to-chuck distance of 50 mm, and thequotient was taken as elongation.

(Young's Modulus)

The Young's modulus of a porous substrate or a separator was measured asfollows. Using a tensile tester (RTC-1225A manufactured by A&D Company),the Young's modulus of a sample adjusted to 10 mm×100 mm was measuredwith reference to JIS K 7161 under the following conditions: load cellload: 5 kgf, chuck-to-chuck distance: 50 mm, tensile rate: 100 mm/min.

(Puncture Resistance)

The puncture resistance of a porous substrate or a separator wasmeasured as follows. A sample was inserted into a metal frame having ahole of ϕ11.3 mm (sample holder) together with a packing made ofsilicone rubber and fixed, and subjected to measurement using HandyCompression Tester KES-G5 (manufactured by Kato Tech Co., Ltd.). Withrespect to the measurement conditions, the needle tip curvature radiuswas 0.5 mm, and the puncture rate was 2 mm/sec. The maximum punctureload was taken as puncture resistance.

(Cycle Characteristics)

A test battery produced below was repeatedly charged and discharged at acharge voltage of 4.2 V and a discharge voltage of 2.75 V. The dischargecapacity at the 100^(th) cycle was divided by the initial capacity, andthe average capacity retention and the range of fluctuation (%) throughrepeated charging and discharging were evaluated as cyclecharacteristics. The evaluation criteria were as follows.

A: Capacity retention is 85% or more, and the range of fluctuation is 7%or less

B: Capacity retention is 85% or more, but the range of fluctuation ismore than 7%

C: Capacity retention is less than 85%, and the range of fluctuation ismore than 7%

(Adhesion to Electrodes)

A test battery was disassembled, and the magnitude of the force requiredto remove each of the negative electrode and the positive electrode fromthe separator was measured using a tensile tester (RTC-1225Amanufactured by A&D Company). Taking the magnitude of the force inExample 1 as 100, adhesion was evaluated as an index. An index of 80 ormore is a practically desired level.

(Slitting Properties)

A separator was transferred under the following conditions: transferrate: 40 m/min, unrolling tension: 0.3 N/cm, rolling tension: 0.1 N/cm.During the horizontal transfer, a razor blade made of stainless steelwas pressed against the separator at an angle of 60° to subject 1,000 mof the separator to a slitting treatment. The external appearance of theend face (slit end face) was visually observed, and the number ofobservable parts that had fallen off during the slitting process wascounted.

<Evaluation Criteria>

A: The number of 0.5-mm or larger chips from an adhesive porous layer is5 or less.

B: The number of 0.5-mm or larger chips from an adhesive porous layer is10 or less.

C: The number of 0.5-mm or larger chips from an adhesive porous layer is20 or less.

D: The number of 0.5-mm or larger chips from an adhesive porous layer ismore than 20.

Example 1

Production of Separator

As an adhesive resin, a vinylidene fluoride/hexafluoropropylenecopolymer (=98.9/1.1 [molar ratio], weight average molecular weight:1,950,000) was used. In addition, a magnesium hydroxide having anaverage particle size of 0.8 μm was used as an inorganic filler, and theratio of the inorganic filler to the polyvinylidene fluoride resin [massratio] was set to 0.01 (=inorganic filler/polyvinylidene fluorideresin).

The polyvinylidene fluoride resin and the magnesium hydroxide in theabove ratio were dissolved to a concentration of 5 mass % in a mixedsolvent of dimethylacetamide and tripropylene glycol (=7/3 [mass ratio])to prepare a coating liquid.

As a porous substrate, a polyethylene microporous membrane (thickness: 9μm, Gurley number: 160 sec/100 cc, porosity: 43%) was used.

Both sides of the polyethylene microporous membrane were coated with thesame amount of the coating liquid obtained as above. Next, a coagulationliquid obtained by mixing water, dimethylacetamide, and tripropyleneglycol (=57/30/13 [mass ratio]) was prepared, and the polyethylenemicroporous membrane was immersed in the coagulation liquid (40° C.) tosolidify the adhesive resin.

It was then washed with water and dried to give a separator having anadhesive porous layer made of a polyvinylidene fluoride resin formed onboth sides of a polyolefin microporous membrane.

With respect to this separator, Table 1 summarizes the physicalproperties of the porous substrate (the mean of thickness, the standarddeviation/mean of thickness, elongation in the MD direction and the TDdirection, puncture resistance, tensile strength in the MD direction andthe TD direction, and Young's modulus), the physical properties of theadhesive porous layer (the weight average molecular weight (MW) of theadhesive resin, filler mass ratio (inorganic filler mass/polyvinylidenefluoride resin mass), the mean and the standard deviation/mean of theareal weight of the adhesive porous layer (total on both sides)), andthe physical properties of the separator (elongation in the MD directionand the TD direction, puncture resistance, tensile strength in the MDdirection and the TD direction, and Young's modulus). In addition, thefollowing examples and comparative examples are also summarized in Table1 similarly.

Production of Nonaqueous Electrolyte Battery

(1) Production of Negative Electrode

300 g of artificial graphite as a negative electrode active material,7.5 g of an aqueous dispersion containing 40 mass % a modifiedstyrene-butadiene copolymer as a binder, 3 g of carboxymethyl celluloseas a thickener, and an appropriate amount of water were stirred in adouble-arm mixer to prepare a slurry for a negative electrode. Theslurry for a negative electrode was applied to a copper foil having athickness of 10 μm as a negative electrode collector, dried, and thenpressed to give a negative electrode having a negative electrode activematerial layer.

(2) Production of Positive Electrode

89.5 g of a lithium cobalt oxide powder as a positive electrode activematerial, 4.5 g of acetylene black as an electrically conductiveauxiliary, and 6 g of polyvinylidene fluoride as a binder were dissolvedin N-methyl-pyrrolidone (NMP) to a polyvinylidene fluoride concentrationof 6 mass %, and stirred in a double-arm mixer to prepare a slurry for apositive electrode. The slurry for a positive electrode was applied toan aluminum foil having a thickness of 20 μm as a positive electrodecollector, dried, and then pressed to give a positive electrode having apositive electrode active material layer.

(3) Production of Battery

A lead tab was welded to the positive electrode and the negativeelectrode. Then, the positive electrode, the separator, and the negativeelectrode were stacked in this order and joined together, impregnatedwith an electrolyte, and enclosed in an aluminum pack using a vacuumsealer. As the electrolyte, a 1 M LiPF₆ mixed solution obtained bymixing ethylene carbonate (EC) and ethylmethyl carbonate (DMC) in a massratio of 3:7 (=EC:DMC) was used.

Using a hot press, a load of 20 kg per cm² of electrode was applied tothe aluminum pack having enclosed therein the electrolyte, and thealuminum pack was hot-pressed at 90° C. for 2 minutes to produce a testbattery (lithium ion secondary battery).

Example 2

A separator was produced in the same manner as in Example 1, except thatthe ratio of the inorganic filler to the polyvinylidene fluoride resin[mass ratio] in Example 1 was changed to 0.03 (=inorganicfiller/polyvinylidene fluoride resin) to adjust the “standard deviationof areal weight/mean of areal weight” of the adhesive porous layer madeof a polyvinylidene fluoride resin to the value shown in Table 1 below.A test battery (lithium ion secondary battery) was then produced.

Example 3

A separator was produced in the same manner as in Example 1, except thatthe ratio of the inorganic filler to the polyvinylidene fluoride resin[mass ratio] in Example 1 was changed to 0.05 (=inorganicfiller/polyvinylidene fluoride resin) to adjust the “standard deviationof areal weight/mean of areal weight” of the adhesive porous layer madeof a polyvinylidene fluoride resin to the value shown in Table 1 below.A test battery (lithium ion secondary battery) was then produced.

Example 4

A separator was produced in the same manner as in Example 1, except thatthe porous substrate in Example 1 was replaced with a polyethylenemicroporous membrane having the physical property values shown in Table1 below. A test battery (lithium ion secondary battery) was thenproduced.

Examples 5 and 6

Separators of Examples 5 and 6 were each produced in the same manner asin Example 1, except that the porous substrate in Example 1 was replacedwith a polyethylene microporous membrane having the physical propertyvalues shown in Table 1 below, and the ratio of the inorganic filler tothe polyvinylidene fluoride resin [mass ratio] was changed to 0.5(=inorganic filler/polyvinylidene fluoride resin). Test batteries(lithium ion secondary batteries) were then produced.

Examples 7 and 8

Separators of Examples 7 and 8 were each produced in the same manner asin Example 1, except that the adhesive resin in Example 1 was replacedwith a vinylidene fluoride/hexafluoropropylene copolymer having a weightaverage molecular weight of 600,000 or 3,000,000. Test batteries(lithium ion secondary batteries) were then produced.

Example 9

As a coating liquid, a coating liquid containing a styrene-butadienecopolymer and carboxymethyl cellulose (styrene-butadienecopolymer:carboxymethyl cellulose:water=3:2:95 [mass ratio]) wasprepared. Both sides of the same polyethylene macroporous membrane as inExample 1 were coated with the same amount of the coating liquid, anddried to give a separator including an adhesive porous layer made of astyrene-butadiene copolymer. The areal weight of the adhesive porouslayer in the obtained separator was 1.9 g/m², and the standarddeviation/mean of areal weight was 0.19.

Comparative Example 1

A separator was produced in the same manner as in Example 1, except thatthe ratio of the inorganic filler to the polyvinylidene fluoride resin[mass ratio] in Example 1 was changed to 0.10 (=inorganicfiller/polyvinylidene fluoride resin) to adjust the “standard deviationof areal weight/mean of areal weight” of the adhesive porous layer madeof a polyvinylidene fluoride resin to the value shown in Table 1 below.A test battery (lithium ion secondary battery) was then produced.

Comparative Examples 2 to 5

Separators of Comparative Examples 2 to 5 were each produced in the samemanner as in Example 1, except that the porous substrate in Example 1was replaced with a polyethylene macroporous membrane having thephysical property values shown in Table 1 below. Test batteries (lithiumion secondary batteries) were then produced.

TABLE 1 Porous Substrate Adhesive Porous Layer Standard Tensile Young'sStandard Deviation/ Elongation Puncture Strength Modulus Filler ArealDeviation/ Thickness Mean of [%] Resistance [N/cm] [GPa] Adhesive ResinMass Weight Mean of Areal [μm] Thickness MD/TD [g] MD/TD MD/TD Kind MwRatio [g/m²] Weight Example 1 9 0.01 82/113 411 20/14 2.4/1.3 PVDF1,950,000 0.01 2.3 0.13 Example 2 9 0.01 82/113 411 20/14 2.4/1.3 PVDF1,950,000 0.03 2.4 0.28 Example 3 9 0.01 82/113 411 20/14 2.4/1.3 PVDF1,950,000 0.05 2.4 0.20 Example 4 9 0.03 81/110 405 21/14 2.4/1.3 PVDF1,950,000 0.01 2.3 0.25 Example 5 9 0.02 100/150  420 22/16 2.3/1.2 PVDF1,950,000 0.5 2.5 0.30 Example 6 9 0.02 150/115  380 19/13 2.0/1.0 PVDF1,950,000 0.5 2.4 0.29 Example 7 9 0.01 82/113 411 20/14 2.4/1.3 PVDF600,000 0.01 2.3 0.28 Example 8 9 0.01 82/113 411 20/14 2.4/1.3 PVDF3,000,000 0.01 2.3 0.29 Comparative 9 0.01 82/113 411 20/14 2.4/1.3 PVDF1,950,000 0.10 2.4 0.40 Example 1 Comparative 12 0.05 210/250  305 19/151.1/0.7 PVDF 1,950,000 0.01 2.3 0.39 Example 2 Comparative 9 0.03 45/120320 22/10 3.1/0.9 PVDF 1,950,000 0.01 2.3 0.35 Example 3 Comparative 300.04 70/100 850 60/44 2.2/1.2 PVDF 1,950,000 0.01 2.3 0.41 Example 4Comparative 12 0.03 110/6   190 26/2  3.0/0.5 PVDF 1,950,000 0.01 2.30.33 Example 5 Separator Tensile Young's Evaluation Elongation PunctureStrength Modulus Adhesion [%] Resistance [N/cm] [GPa] to Cycle SlittingMD/TD [g] MD/TD MD/TD Electrodes Characteristics Properties Example 181/112 421 21/15 1.8/0.9 100  A A Example 2 83/115 428 20/13 1.8/0.9 83A B Example 3 84/115 425 22/15 1.9/0.9 98 A A Example 4 80/110 415 21/141.8/0.9 93 A A Example 5 115/140  430 23/17 1.8/0.9 79 A B Example 6157/125  390 20/14 1.7/0.7 79 A B Example 7 81/112 418 21/15 1.8/0.9 81A B Example 8 81/112 425 21/15 1.8/0.9 80 A B Comparative 79/105 42424/15 1.9/1.0 75 C C Example 1 Comparative 210/250  318 20/16 0.9/0.5 75C C Example 2 Comparative 44/130 331 23/11 2.4/0.7 76 B B Example 3Comparative 65/95  880 61/45 2.0/1.0 74 C B Example 4 Comparative105/5   195 27/2  2.8/0.3 76 B B Example 5

As shown in Table 1, in the examples, because the “standard deviation ofareal weight/mean of areal weight” of an adhesive porous layer is withinthe predetermined range, the results show excellent adhesion toelectrodes, excellent cycle characteristics, and excellent slittingproperties as compared with the comparative examples. Incidentally, theevaluation results of Example 9 were also at the same level as inExample 1.

What is claimed is:
 1. A separator for a nonaqueous electrolyte battery,comprising a porous substrate and an adhesive porous layer that isprovided on one side or both sides of the porous substrate and containsan adhesive resin, the ratio of the standard deviation of the arealweight of the adhesive porous layer to the mean of the areal weight ofthe adhesive porous layer (g/m²) (standard deviation/mean) being 0.25 orless, wherein the porous substrate has a mean thickness in a range of 5μm to 9 μm, and the ratio of the standard deviation of the thickness ofthe porous substrate to the mean of the thickness of the poroussubstrate (μm) (standard deviation/mean) is 0.02 or less.
 2. Theseparator for a nonaqueous electrolyte battery according to claim 1,wherein the adhesive resin is a polyvinylidene fluoride resin.
 3. Theseparator for a nonaqueous electrolyte battery according to claim 2,wherein the polyvinylidene fluoride resin has a weight average molecularweight of 600,000 or more and 3,000,000 or less.
 4. The separator for anonaqueous electrolyte battery according to claim 1, wherein the poroussubstrate has an elongation of 50% or more and 200% or less in the MDdirection or the TD direction.
 5. The separator for a nonaqueouselectrolyte battery according to claim 1, wherein the porous substratehas a puncture resistance of 200 g or more and 800 g or less.
 6. Theseparator for a nonaqueous electrolyte battery according to claim 1,wherein the adhesive porous layer contains a filler, and the mass ratioof the filler to the adhesive resin (filler mass/adhesive resin mass) is0.01 or more and 0.05 or less.
 7. A nonaqueous electrolyte batterycomprising a positive electrode, a negative electrode, and the separatorfor a nonaqueous electrolyte battery of claim 1 disposed between thepositive electrode and the negative electrode, an electromotive forcethereof being obtained by lithium doping/dedoping.
 8. A separator for anonaqueous electrolyte battery, comprising a porous substrate and anadhesive porous layer that is provided on one side or both sides of theporous substrate and contains an adhesive resin, the ratio of thestandard deviation of the areal weight of the adhesive porous layer tothe mean of the areal weight of the adhesive porous layer (g/m²)(standard deviation/mean) being 0.25 or less, wherein the poroussubstrate has a mean thickness in a range of 5 μm to 9 μm, and theadhesive resin is a polyvinylidene fluoride resin that has a weightaverage molecular weight of 600,000 or more and 3,000,000 or less. 9.The separator for a nonaqueous electrolyte battery according to claim 8,wherein the ratio of the standard deviation of the thickness of theporous substrate to the mean of the thickness of the porous substrate(μm) (standard deviation/mean) is 0.01 or less.
 10. The separator for anonaqueous electrolyte battery according to claim 8, wherein the poroussubstrate has an elongation of 50% or more and 200% or less in the MDdirection or the TD direction.
 11. The separator for a nonaqueouselectrolyte battery according to claim 8, wherein the porous substratehas a puncture resistance of 200 g or more and 800 g or less.
 12. Theseparator for a nonaqueous electrolyte battery according to claim 8,wherein the adhesive porous layer contains a filler, and the mass ratioof the filler to the adhesive resin (filler mass/adhesive resin mass) is0.01 or more and 0.05 or less.
 13. A nonaqueous electrolyte batterycomprising a positive electrode, a negative electrode, and the separatorfor a nonaqueous electrolyte battery of claim 8 disposed between thepositive electrode and the negative electrode, an electromotive forcethereof being obtained by lithium doping/dedoping.